Update on this, for those who are interested.

Removal of the alternator cannot be done without removal of the throttle body as well (the instructions fail to mention this). Additionally, there is a metal bracket preventing the removal of the lower bolt that runs from the intake manifold down to the block - I am going to try and pick up a Haynes manual or something and see what that says.

The pictures from this link: http://www.justanswer.com/questions/...-my-2004-chevy (free registration) show what I'm referring to (the last picture in the removal section, same as first picture in the installation section). That long bolt is stopped about 1/4-1/2" from being able to come out. At this point I am thinking the intake manifold must come out as well.

Actually, looking at the picture again, I think maybe that lower bracket piece may come out after all. From what I could see (precious little, even with mirror-on-a-stick and flashlight), that appeared to be a large mount of some sort - but I could be mistaken. Will try again tomorrow and update.

Also - for cars equipped with AC - the AC lines are directly in the way of a clear removal, hence having to remove the TB.


The only thankful note so far is that no bolts have snapped (knock on wood).